Flexible Substrate Curved Light-Emitting Device Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing light-emitting devices with curved surfaces face challenges such as luminance unevenness, short circuits, and increased weight or cost due to the need for shape-holding plates, especially when dealing with complex curved surfaces or flexible organic EL elements.
Innovation Solution
A method involving a flexible substrate with a desired curved surface, supported in a flat plate-like shape, where the light-emitting element is formed and then deformed to match the curved surface without using additional shape-holding plates, utilizing either spontaneous deformation or heat-shrinkable substrates to achieve the curved shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a substrate is molded into a curved shape in advance to form a light-emitting device with a curved surface, then the light-emitting region can be formed on a curved surface, but the thickness of the light-emitting layer becomes uneven causing luminance unevenness or short circuits
Solution Approach 1:
The substrate is prepared with a predetermined curved shape before forming the light-emitting layer, allowing the layer to be formed conformally on the curved surface. This preliminary shaping enables subsequent uniform deposition of the light-emitting layer while maintaining the desired curved geometry, preventing thickness variations that would cause luminance unevenness or short circuits.
2Shape
If shape-holding plates are used to curve a flexible organic EL element, then the element can be curved in accordance with complex curved surfaces, but the weight and cost increase
Solution Approach 1:
The invention extracts and removes the shape-holding plates from the final device structure. Instead of using additional plates to maintain the curved shape, the substrate itself is pre-formed with the desired curved geometry, eliminating the need for separate weight-adding components while maintaining the ability to conform to complex curved surfaces.
Solution Approach 2:
The substrate serves multiple functions: it provides structural support, defines the curved shape, and serves as the base for forming the light-emitting layer. By integrating the shape-holding function into the substrate itself rather than requiring separate plates, the device achieves weight reduction while maintaining the ability to conform to various curved surfaces.
3Shape
If shape-holding plates are used to curve a flexible organic EL element, then the element can be curved in accordance with complex curved surfaces, but the cost increases
Solution Approach 1:
The invention extracts and removes the shape-holding plates from the device structure, eliminating the cost associated with manufacturing and assembling these additional components. The substrate alone provides the necessary shape-holding capability, reducing material costs and simplifying the manufacturing process.
Solution Approach 2:
The invention discards the concept of using separate shape-holding plates that would need to be manufactured, assembled, and potentially disposed of. Instead, the shape-holding function is integrated into the substrate that is already present in the device, eliminating redundant manufacturing steps and associated costs.
4Shape
If the flexible substrate is deformed after forming the light-emitting element, then the light-emitting region can be provided on a curved surface without additional plates, but deformation control must be precise to avoid damaging the light-emitting element
Solution Approach 1:
The substrate is pre-formed with the desired curved shape before the light-emitting layer is deposited. This preliminary action ensures that when the light-emitting element is formed and the substrate is subsequently deformed to its final curved configuration, the light-emitting layer has already been formed on a conformal surface, reducing stress concentration and preventing damage during the deformation process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the creation of lightweight light-emitting devices with a light-emitting region on a curved surface, preventing defects like luminance unevenness and short circuits while reducing material and weight, allowing for complex curved surface adaptations without additional deformation aids.
Implementation Method 1
a flexible substrate provided with a desired curved surface in advance; a second step of forming a light-emitting element which includes a layer containing a light-emitting organic compound between a pair of electrodes so as to be in contact with the flexible substrate supported in a flat plate-like shape; and a third step of deformation or return of a portion of the flexible substrate where a light-emitting region of the light-emitting element is provided into a shape having a curved surface
Data Source
AI summary
To provide a method for manufacturing a lightweight light-emitting device having a light-emitting region on a curved surface. The light-emitting region is provided on a curved surface in such a manner that a light-emitting element is formed on a flexible substrate supported in a plate-like shape and the flexible substrate deforms or returns.